Golf balls comprising non-ionomeric fluoropolymer

ABSTRACT

A golf ball comprising a core, a cover, and an intermediate layer disposed between the core and the cover, wherein the intermediate layer comprises a non-ionomeric fluoropolymer having a formula:  
                 
 
     wherein X 1  to X 12  are hydrogen, fluorine, chlorine, bromine, iodine, CH 3 , CF 3 , linear or branched alkyl group, partially fluorinated or perfluorinated alkyl group, linear or branched alkoxy group, partially fluorinated or perfluorinated alkoxy group, aromatic, or alicyclic; at least one of X 1  to X 4  comprises a fluorine; m ranges from 100 to 1 percent by weight of the fluoropolymer; n ranges from 0 to 50 percent by weight of the fluoropolymer; and o ranges from 0 to 35 percent by weight of the fluoropolymer.

CROSS-REFERENCE TO RELATED APPLICATIONS

[0001] This application is a continuation of co-pending U.S. applicationSer. No. 10/171,355, which was filed June 13, 2002.

FIELD OF THE INVENTION

[0002] This invention relates generally to golf balls, and morespecifically, to a multi-layer golf ball and a composition thereforecomprising at least one non-ionomeric fluoropolymer.

BACKGROUND OF THE INVENTION

[0003] Solid core golf balls are well known in the art. Typically, thecore is made from polybutadiene rubber material, which provides theprimary source of resiliency for the golf ball. A known drawback ofpolybutadiene cores cross-linked with peroxide and/or zinc diacrylate isthat this material is adversely affected by absorption of water vapor,which reduces the resiliency of the cores and degrades their properties.Thus, these cores must be covered quickly to maintain optimum ballproperties. A cover that protects the core from the elements andrepeated impacts from golf clubs is typically made from ionomer resins,balata, and urethane, among other materials, lonomer covers,particularly hard ionomers, offer some protection against the absorptionof water vapor. However, it is more difficult to control or impart spinto balls with hard covers. Conventional urethane covers provide betterball control but offer less resistance to water vapor than ionomercovers.

[0004] Prolonged exposure to high humidity and elevated temperature maybe sufficient to allow water vapor to invade the cores of somecommercially available golf balls. For example, at 38° C. and 90%humidity over a sixty day period, significant amounts of moisture enterthe cores and reduce the initial velocity of the balls by 1.8 ft/s to4.0 ft/s or greater. The change in compression may be reduced by 5% ormore. The absorbed water vapor also reduces the golf ball coefficient ofrestitution (“COR”). When a golf ball is subjected to prolonged storageand/or use under ambient conditions such as 25-35% RH, as well asconditions of high temperature and high humidity, the COR of the golfball tends to decrease over time due to water vapor absorption.

[0005] Several prior patents have addressed the water vapor absorptionproblem. U.S. Pat. No. 5,820,488 discloses a golf ball having a watervapor barrier (“WVB”) layer disposed between a core and a cover. The WVBlayer may comprise polyvinylidene chloride (“PVDC”) or vermiculite. Itcan also be formed by an in situ reaction between a barrier-formingmaterial and the outer surface of the core. U.S. Pat. Nos. 5,885,172 and6,132,324 disclose, among other things, a golf ball with a polybutadieneor wound core having an ionomer inner cover and a relatively soft outercover. The hard ionomer inner cover offers some resistance to watervapor absorption, while the soft outer cover provides desirable ballcontrol. U.S. Pat. No. 6,232,389 discloses the application of adispersed exfoliated layered filler in an elastomeric polymer basedbarrier coating mixture so as to reduce water vapor permeability in golfballs and other objects by at least 5-fold. Preferable fillers includelayered silicates such as bentonite and vermiculite. U.S. Pat. No.6,287,216 discloses a wounded golf ball having a liquid centersurrounded by a thermoplastic core layer formed of a hydrophobicmaterial that has a water vapor permeation rate of less than about 170g-mil/100 in²·24 h.

[0006] Prior art referenced above typically resort to the incorporationof a WVB material in an existing layer or a designated WVB layer toovercome the water vapor absorption problem in golf balls, escalatingmanufacturing cost and construction complexity. It is thereforedesirable to provide cost-effective material compositions that havegeneral characteristics suitable for golf ball constructions withconcomitant WVB properties.

[0007] One particular class of polymers suitable for golf ballcompositions of the present invention is fluoropolymers. Fluoropolymersare well known for their excellent resistance to outdoor weathering andultraviolet irradiation, high degree of physical toughness, chemicalinertness, water and gas impermeability, low moisture absorption, goodabrasion resistance, non-tackiness, resistance to soiling, as well as asignificant retention of these properties at both low and elevatedtemperatures. This rare combination is due to the strength of the C—Fbond, one of the most stable bonds known. Other desirable properties ofthe fluoropolymers include high elongation, low coefficient of friction,low wear rate, good resistance to swell in solvents, low refractiveindex, and low dielectric constant. These desirable properties allow thefluoropolymers to be widely used as self-supporting layers or outercoatings on various substrates.

[0008] Disclosures of fluoropolymer applications in golf ballcompositions, however, are limited. U.S. Pat. No. 5,962,140 describes agolf ball having a core and/or an intermediate layer comprising afunctionalized fluoropolymer wherein the fluoropolymer may be anionomeric perfluoropolymer that is sulfonated or carboxylated or aderivative thereof U.S. Pat. No. 6,133,389 discloses amorphoustetrafluoroethylene-hexafluoropropylene (“TFE-HFP”) dipolymers, andother copolymers containing TFE, HFP and a third monomer, useful ascoatings for golf balls. U.S. Pat. No. 6,217,464 discloses a golf ballhaving a lubricating material on its surface for reducing the spinimparted by a striking golf club. The lubricating material may befluoropolymer, and the coating thickness is less than about 0.010inches.

[0009] There remains a need, however, for further development of golfball compositions comprising fluoropolymers, particularly non-ionomericfluoropolymers (“NIFP”), in multi-layer golf ball constructions.

SUMMARY OF THE INVENTION

[0010] The present invention is directed in general to golf ball, andparticularly to golf ball compositions and constructions. Specifically,the invention is direct to a multi-layer golf ball comprising a core, acover, and an intermediate layer disposed between the core and thecover, wherein the intermediate layer comprises a non-ionomericfluoropolymer having a formula:

[0011] wherein X₁ to X₁₂ are hydrogen, fluorine, chlorine, bromine,iodine, CH₃, CF₃, linear or branched alkyl group, partially fluorinatedor perfluorinated alkyl group, linear or branched alkoxy group,partially fluorinated or perfluorinated alkoxy group, aromatic, oralicyclic; at least one of X₁ to X₄ comprises a fluorine; m ranges from100 to 1 percent by weight of the NIFP; n ranges from 0 to 50 percent byweight of the NIFP; and o ranges from 0 to 35 percent by weight of theNIFP.

[0012] The NIFP may be a homopolymer, copolymer, or terpolymercomprising one or more non-ionomeric fluoromonomers. Suitablenon-ionomeric fluoromonomers are partially fluorinated or perfluorinatedethylenic monomers and include, but are not limited to, fluorinatedolefins of from about 1 to about 12 carbon atoms, such as vinylidenefluoride, vinyl fluoride, hexafluoropropylene, pentafluoropropylene,tetrafluoropropylene, trifluoropropylene, difluoropropylene,tetrafluoroethylene, trifluoroethylene, 1,2-difluoroethylene,chlorotrifluoroethylene, 1,2-dichlorodifluoroethylene,1-chloro-1-fluoroethylene, and perfluorobutyl ethylene; fluorinatedalkyl α-olefins such as 3,3,3,4,4-pentafluoro-1-butene,3,3,3-trifluoropropene, 1-hydropentafluoropropene,2-hydropentafluoropropene, and2-trifluoromethyl-3,3,3-trifluoro-1-propene; fluorinated vinyl ethers offrom about 1 to about 8 carbon atoms, such asperfluoro(methylvinylether), perfluoro(ethylvinylether) andperfluoro(propylvinylether); perfluorodioxoles of from about 1 to about10 carbon atoms, such as perfluoro(1,3-dioxole) andperfluoro(2,2-dimethyl-1,3-dioxole); fluorinated dienes of from about 1to about 8 carbon atoms, such as fluorinated derivatives of1,4-butadiene and cis-isoprene, fluorinated acrylics including1,1-dihydropentadecafluorooctylacrylate and1,1-dihydropentadienefluorooctylacrylate; perfluoralkoxy;fluorosilicons; perfluorocyclics; and mixtures thereof. Preferred NIFP'sfor the golf ball compositions of the present invention are vinylidenefluoride homopolymer, vinylidene fluoride/hexafluoropropylene copolymer,and vinylidene fluoride/hexafluoropropylene/tetrafluoroethyleneterpolymer.

[0013] In accordance with conventional fluoropolymer chemistry, the NIFPof the invention may further comprise cure site monomers; ionomericfluoropolymers, chain transfer agents; peroxide curatives; aminecuratives; bisphenol curatives; cross-linking agents; redox initiators;co-curing agents; dispersion fillers; density-modifying fillers; foamingagents; antioxidants; reinforcing agents; plasticizers; lubricants;processing aids; pigments and dyes; and mixtures thereof. The NIFP canalso blend with a thermoplastic material to form the intermediate layerin golf balls. Suitable thermoplastic materials include withoutlimitation polyesterester block copolymers, polyetherester blockcopolymers, polyetheramide block copolymers, partially or fullyneutralized ionomer resins, dynamically vulcanized thermoplasticelastomers, hydrogenated styrene-butadiene elastomers with functionalgroups attached, thermoplastic polyurethanes, thermoplastic polyesters,metallocene polymers; styrene-propylene-diene rubbers; polybutadienes;chloroprene rubbers; acrylonitrile rubbers; acrylonitrile-butadienerubbers; ethylene/proprylene/diene terpolymers; polypropylene resins;epoxy; polyurea; styrene-ethylene block copolymers; maleic anhydride orsuccinate modified metallocene catalyzed ethylene copolymers;chlorinated polyethylenes; polysulfide rubbers; fluorocarbons;polymethylmethacrylate, and mixtures thereof. In one embodiment of thepresent invention, the intermediate layer comprises about 10% to about75% by weight of the NIFP, about 0% to about 25% by weight of thethermoplastic material, and about 0% to about 50% by weight of adensity-modifying filler.

[0014] Preferably, the NIFP-based intermediate layer has a flexuralmodulus between about 30,000 psi and about 150,000 psi, more preferablybetween about 55,000 psi and about 75,000 psi; a material hardnessbetween about 25 and about 75 Shore D, more preferably between about 50and about 70 Shore D; a thickness between about 0.005 inches and about0.085 inches, more preferably between about 0.030 inches and about 0.060inches; an outer diameter between about 1.500 inches and about 1.650inches, more preferably between about 1.550 inches and about 1.640inches. The intermediate layer may further comprise a density-reducingfiller to adjust its specific gravity to between about 0.90 and about1.50. In one embodiment, the intermediate layer is either an outer corelayer or an inner cover layer.

[0015] In another embodiment of the present invention, the corecomprises a center and at least one outer core layer. Optionally, the atleast one outer core layer also comprises a NIFP. The center may besolid, hollow, liquid-filled, gel-filled, or gas-filled, while the outercore layer may be a wound layer. Preferably, the core has a compressionof less than about 60 and a Shore D hardness of less than about 60.

[0016] In a further embodiment, the cover comprises an outer cover layerand at least one inner cover layer. Optionally, the at least one innercover layer comprises a NIFP. Cover materials of the present inventionare typically thermoplastic or thermosetting materials, used alone orblended with the optional NIFP. Suitable materials for forming the coverlayers include, but are not limited to, partially or fully neutralizedionomer resins; epoxy; polyurethanes; balata; vinyl resins; polyolefins;polyureas; polyamides; acrylic resins and blends thereof; blockcopolymers; copoly(ether-amide); polyphenylene oxide resins and blendsthereof; thermoplastic polyesters; and mixtures thereof.

[0017] The present invention further directs to a two-piece golf ballcomprising a core and a cover. Preferably, the cover comprises a NIFP asdescribed herein, such as vinylidene fluoride homopolymer, vinylidenefluoride/hexafluoropropylene copolymer, or vinylidenefluoride/hexafluoropropylene/tetrafluoroethylene terpolymer. Athermoplastic or thermosetting material may be blended with the NIFP toform the cover, including partially or fully neutralized ionomer resins;epoxy; polyurethanes comprising polyols and polyisocyanates; balata;vinyl resins; polyolefins; polyureas; polyamides; acrylic resins andblends thereof; block copolymers; copoly(ether-amide); polyphenyleneoxide resins and blends thereof; thermoplastic polyesters; blends andalloys including polycarbonate with acrylonitrile butadiene styrene andpolyvinyl chloride with acrylonitrile butadiene styrene; blends ofthermoplastic rubbers with polyethylene and propylene; and mixturesthereof. Other conventional additives for golf ball cover may beincorporated herein. Such additives include without limitationantioxidants; catalysts; colorants including pigments and dyes; hinderedamine light stabilizers; optical brighteners; UV absorbers; fillers;metals; plasticizers; surfactants; viscosity modifiers; compatibilityagents; dispersing agents; foaming agents; reinforcement agents; releaseagents; and mixtures thereof. Optionally, the core of the two-piece golfball may comprise a center and at least one outer core layer.

[0018] In yet another embodiment of the present invention, a three-piecegolf ball comprises a core, a cover, and an intermediate layer disposedbetween the core and the cover. At least one of the intermediate layeror the cover comprises a NIFP having a water absorption of less thanabout 0.07%. Preferably, the core has a compression of less than about60, and the intermediate layer has a material hardness greater than thatof the cover by at least about 10 Shore D.

DEFINITIONS

[0019] The following terms that are used in this application are definedin terms of the enumerated ASTM tests: Specific Gravity ASTM D-792,Flexural Modulus ASTM D-790, Shore D Hardness ASTM D-2240, and Shore CHardness ASTM D-2240. The ASTM D-792 test was carried out in labconditions where the temperature was controlled to 20-23° C.

[0020] As used herein, the terms “points” and “compression points” referto the compression scale or the compression scale based on the ATTIEngineering Compression Tester. This scale, which is well known to thoseworking in this field, is used in determining the relative compressionof a core or ball.

[0021] As used herein, “COR” refers to Coefficient of Restitution, whichis obtained by dividing a ball's rebound velocity by its initial (i.e.,incoming) velocity. This test is performed by firing the samples out ofan air cannon at a vertical steel plate over a range of test velocities(from 75 to 150 ft/s). A golf ball having a high COR dissipates asmaller fraction of its total energy when colliding with the plate andrebounding therefrom than does a ball with a lower COR. Unless otherwisenoted, the COR values reported herein are the values determined at anincoming velocity of 125 ft/s.

[0022] As used herein, the terms “fluoropolymer” and “fluorinatedpolymer” is defined as any themoplastic and/or elastomeric homopolymer,copolymer, terpolymer, or mixture thereof, having at least one fluorinein at least one of the monomer repeat units in the polymer.

[0023] As used herein, the terms “fluoromonomer” and “fluorinatedmonomer” refer to compounds containing an ethylinic group that may befree-radically polymerized and that contain at least one fluorine atom,fluoroalkyl group, or fluoroalkoxy group attached to the ethylinic groupthat undergoes polymerization.

[0024] As used herein, the term “copolymer” refers to a polymer which isformed from two or more monomers, wherein the monomers are notidentical.

[0025] As used herein, the term “terpolymer” refers to a polymer whichis formed from three monomers, wherein the monomers are not identical.

[0026] As used herein, the term “fillers” includes any compound orcomposition that can be used to vary the density and other properties ofthe subject golf ball cores.

[0027] As used herein, the term “pph” in connection with a batchformulation refers parts by weight of the constituent per hundred partsof the base composition (e.g., elastomer).

[0028] The term “about,” as used herein in connection with one or morenumbers or numerical ranges, should be understood to refer to all suchnumbers, including all numbers in a range.

DETAILED DESCRIPTION OF THE INVENTION

[0029] The golf balls of the present invention may comprise any of avariety of constructions, such as a two-piece, three-piece, multi-layer,or wound ball having a variety of cores, intermediate layers, covers,and coatings. The covers and cores of the present invention includestructures comprising one or more layers. Cores may include a single,unitary layer, comprising the entire core from the center of the core toits outer periphery, or may contain a center surrounded by at least oneouter core layer. The center, the innermost portion of the core, ispreferably solid, but may be hollow or liquid-, gel-, or gas-filled. Theouter core layer may also be a wound layer formed of a tensionedelastomeric material. Cover layers of the present invention may alsocontain one or more layers, such as a double cover comprising an innerand outer cover layer. Optionally, an intermediate layer disposedbetween the core and cover may be incorporated. The intermediate layer,if present, may comprise one or more layers, and are sometimes referredto in the art, and, thus, herein as well, as inner cover layers, outercore layers, or mantle layers.

[0030] Any of the core, cover, or the intermediate layer components maybe formed of or include a NIFP, but preferably, at least one of theouter core layer, intermediate layer, inner cover layer, or outer coverlayer comprises a NIFP.

[0031] The NIFP may be a homopolymer, a copolymer, a terpolymer, or amixture thereof that comprises at least one non-ionomeric fluoromonomer.Preferably, the NIFP of the present invention has a formula:

[0032] wherein X₁ to X₁₂ are hydrogen, fluorine, chlorine, bromine,iodine, CH₃, CF₃, linear or branched alkyl group, partially fluorinatedor perfluorinated alkyl group, linear or branched alkoxy group,partially fluorinated or perfluorinated alkoxy group, aromatic, oralicyclic; at least one of X₁ to X₄ comprises a fluorine; m ranges from100 to 1 percent by weight of the NIFP; n ranges from 0 to 50 percent byweight of the NIFP; and o ranges from 0 to 35 percent by weight of theNIFP.

[0033] Non-ionomeric fluoromonomers of the present invention typicallyare partially fluorinated and perfluorinated ethylenic monomers.Examples of such fluoromonomers include, but are not limited to,partially fluorinated and perfluorinated olefins of from about 1 toabout 12 carbon atoms such as vinylidene fluoride (“VDF”); vinylfluoride (“VF”), hexafluoropropylene (“HFP”); pentafluoropropylene(“PFP”); tetrafluoropropylene; trifluoropropylene (“TFP”);difluoropropylene; tetrafluoroethylene (“TFE”); trifluoroethylene;1,2-difluoroethylene; chlorotrifluoroethylene (“CTFE”);1,2-dichlorodifluoroethylene; 1-chloro-1-fluoroethylene; perfluorobutylethylene (“PFBE”); fluorinated alkyl α-olefins such as3,3,3,4,4-pentafluoro-1-butene; 3,3,3-trifluoropropene;1-hydropentafluoropropene; 2-hydropentafluoropropene;2-trifluoromethyl-3,3,3-trifluoro-1-propene; fluorinated vinyl ethers offrom about 1 to about 8 carbon atoms such as perfluoro(methylvinylether)(“PMVE”); perfluoro(ethylvinylether) (“PEVE”);perfluoro(propylvinylether) (“PPVE”); perfluorodioxoles of from about 1to about 10 carbon atoms such as perfluoro(1,3-dioxole) andperfluoro(2,2-dimethyl-1,3-dioxole) (“PDD”); partially fluorinated andperfluorinated dienes of from about 1 to about 8 carbon atoms such asfluorinated derivatives of 1,4-butadiene and cis-isoprene;perfluoralkoxy (“PFA”); fluorosilicons; perfluorocyclics; fluorinatedacrylics such as 1,1-dihydropentadecafluorooctylacrylate and1,1-dihydropentadienefluorooctylacrylate; and mixtures thereof. Othersuitable fluoromonomers for the invention are described in U.S. Pat.Nos. 6,177,196; 5,981,673; 5,654,373; 5,426,165; 4,138,426; and4,452,998, the disclosures of which are incorporated herein by referencein their entirety.

[0034] The non-inonomeric fluoromonomers enlisted above may bepolymerized alone to form a NIFP homopolymer if the fluoromonomer can behomopolymerized. Alternatively, the non-ionomeric fluoromonomer may bepolymerized with one or more other fluoromonomers or other fluorine-freemonomers to form a copolymer, or terpolymer. Suitable fluorine-freemonomers include without limitation substituted and unsubstitutedolefins of from about 1 to about 12 carbon atoms such as ethylene andpropylene and isobutylene; vinyl esters of from about 1 to about 12carbon atoms such as vinyl acetate and vinylpropionate; dienes of fromabout 1 to about 8 carbon atoms such as 1,4-butadiene and cis-isoprene;and mixtures thereof. A preferred NIFP homopolymer for the invention ispolyvinylidene fluoride (“PVDF”), a preferred NIFP copolymer is VDF-HFPcopolymer, and a preferred NIFP terpolymer is VDF-HFP-TFE terpolymer.

[0035] The NIFP's of this invention may include any cure site monomersand their halogenated derivatives commonly used in fluoropolymers,including but not limited to the non-ionomeric fluoromonomers listedabove and derivatives thereof, as well as brominated and iodinatedolefins such as 4-bromotetrafluorobutene-1, bromotrifluoroethylene,4-iodotetrafluorobutene-1, and iodotrifluoroethylene. The NIFP mayfurther be blended with ionomeric fluoropolymers of U.S. Pat. Nos.6,300,445 and 5,962,140, the disclosures of which are incorporatedherein by reference in their entirety. Other additives may also be addedto the NIFP to enhance processability or various physical properties,such as tensile strength, flexural modulus, or water resistance. Asknown to one of ordinary skill in the art, such additives includewithout limitation chain transfer agents, peroxide curatives, aminecuratives, bisphenol curatives, cross-linking agents, redox initiators,co-curing agents, dispersion fillers, density-modifying fillers, foamingagents, antioxidants, reinforcing agents, plasticizers, lubricants,processing aids, pigments and dyes, and mixtures thereof.

[0036] Most of the above mentioned NIFP's are commercially available orcan be prepared by methods well known in the art. For example, AtofinaChemicals, Inc. supplies VDF homopolymers under the trademark of Kynar®PVDF, VDF-HFP copolymers under the trademarks of Kynar Flex® and KynarSuperFlex®, fluorinated acrylic copolymers under the trademark ofForaperle®, and CTFE homopolymers under the trademark of Voltalef®. E.I. du Pont de Nemours and Company produces TFE homopolymers under thetrademark of Teflon® PTFE, TFE-PPVE copolymers under the trademark ofTeflon® NXT, ethylene-TFE copolymer under the trademark of Tefzel® ETFE,TFE-HFP copolymers under the trademark of Teflon® FEP, fluoroelastomerssuch as VDF-HFP copolymers under the trademark of Viton®, PFA copolymersunder the trademark of Teflon® PFA, perfluorocyclopolymers under thetrademark of Teflon® AF, and perfluoroelastomers under the trademark ofKalrez®. 3M provides VDF-HFP copolymers and VDF-HFP-TFE terpolymersunder the trademark of Dyneon®. Ausimont supplies VDF homopolymers underthe trademark of Hylar®, VDF-HFP copolymers and VDF-HFP-TFE terpolymersunder the trademark of Tecnoflon®, ethylene-CTFE copolymers under thetrademark of Halar®, modified ethylene-CTFE under the trademark ofVatar®, TFE-PFA copolymers and PFA homopolymers under the trademark ofHyflon®, and TFE homopolymers under the trademarks of Algoflon® andPolymist®. Daikin Industries, Ltd. produces VDF homopolymers under thetrademark of Neoflon® PVDF, VDF-HFP copolymers and VDF-HFP-TFEterpolymers under the trademark of Dai-El®, TFE homopolymers under thetrademark of Polyflon® PTFE, TFE-PAVE copolymers under the trademark ofNeoflon® PFA, TFE-HFP copolymers under the trademark of Neoflon® FEP,and CTFE homopolymers under the trademark of Neoflon® PCTFE. Asahi GlassCompany manufactures ethylene-TFE copolymers, TFE homopolymers, and PFAhomopolymers under the trademark of Fluon®, FEVE alternating copolymersunder the trademark of Lumiflon®, propylene-TFE alternating copolymersunder the trademark of Aflas®, and amorphous perfluorocyclopolymersunder the trademark of Cytop®. Other commercial NIFP's include TFE-basedfluoropolymers the trademarks of Lubriflon® and Valflon® available fromDixon Resine. Preferably the NIFP's for the present invention are VDFhomopolymers and VDF-HFP copolymers available from Atofina Chemicals,Inc. under the trademark of Kynar Flex®. Specific examples and theirproperties are listed in Table I below. TABLE I Physical and mechanicalproperties of Kynar Flex ® PVDF Properties Series 2500 Series 2750/2950Series 2800/2900 Series 2850 Series 3120 Specific Gravity 1.80-1.821.78-1.80 1.76-1.79 1.76-1.79 1.76-1.79 Water Absorption (%) 0.04-0.070.04-0.07 0.03-0.05 0.03-0.05 0.03-0.05 Flexural Modulus (psi) 28,000-49,000-58,000 90,000-120,000 160,000- 90,000- 36,000 180,000 120,000Hardness (Shore D) 55-60 62-67 65-70 70-75 65-70

[0037] In one embodiment of the present invention, the intermediatelayer is formed from a composition comprising at least one NIFPdescribed above and a thermoplastic material. Suitable thermoplasticmaterials for use in the intermediate layer composition include, but arenot limited to, polyesterester block copolymers, polyetherester blockcopolymers, polyetheramide block copolymers, partially or fullyneutralized ionomer resins, dynamically vulcanized thermoplasticelastomers, hydrogenated styrene-butadiene elastomers with functionalgroups such as maleic anhydride or sulfonic acid attached, thermoplasticpolyurethanes, thermoplastic polyesters, polymers formed using ametallocene catalyst (“metallocene polymers”); styrene-propylenedienerubbers; polybutadienes; chloroprene rubbers; acrylonitrile rubbers;acrylonitrile-butadiene rubbers; EPDM; polypropylene resins; epoxy;polyureas; styrene-ethylene block copolymers; maleic anhydride orsuccinate modified metallocene catalyzed ethylene copolymers;chlorinated polyethylenes; polysulfide rubbers; fluorocarbons such ashexafluoroacetone; polymethylmethacrylate (“PMMA”), and blends thereof.Any of these materials having one or more acidic or ionic moieties maybe partially or fully neutralized, preferably by at least about 40%,more preferably by at least about 70%, and most preferably by about100%.

[0038] Suitable thermoplastic polyetheresters include Hytrel® 3078,G3548W and G4078W from E. I. du Pont de Nemours and Company. Suitablethermoplastic polyetheramides include Pebax® 2533, 1205 and 4033 fromAtofina Chemicals, Inc. Suitable thermoplastic ionomer resins includeany number of olefinic based ionomers such as Surlyn® and Iotek®.Suitable dynamically vulcanized thermoplastic elastomers includeSantoprene®, Sarlink®, Vyram®, Dytron®, and VistaFlex®. Examples ofsuitable functionalized hydrogenated styrene-butadiene elastomers havingfunctional groups such as maleic anhydride or sulfonic acid, includeKraton® FG-1901x and FG-1921x from Shell Corporation. Examples ofsuitable thermoplastic polyurethanes include Estane® 58133, 58134 and58144 from B.F. Goodrich Company. Suitable metallocene-catalyzedpolymers include those commercially available from Sentinel Products.Suitable thermoplastic polyesters include poly(butylene terephthalate),poly(ethylene terepthalate), and poly(trimethylene terepthalate).Preferably the thermoplastic material of the intermediate layercomposition is a polyetherester block copolymer, with Hytrel® 3078 beinga particularly preferred polyetherester block copolymer.

[0039] In accordance to the present invention, the NIFP homopolymers,copolymers and terpolymers described herein may be used in forming anygolf ball component layers such as outer core layers and intermediatelayers, as well as in covers, including inner and outer cover layers.The intermediate layers of the present invention are formed from anintermediate layer composition comprising up to 100% by weight of aNIFP. In one embodiment of the present invention, the intermediate layeris formed from a composition of about 1% to about 99% by weight of aNIFP, about 0% to about 75% by weight of a thermoplastic as describeabove, and about 0% to about 50% by weight of a density-modifying fillersuch as zinc oxide. In another embodiment, the intermediate layer isformed from a composition of about 10% to about 75% by weight of a NIFP,about 0% to about 25% by weight of a thermoplastic, and about 5% toabout 40% by weight of zinc oxide. Most preferably, the intermediatelayer of the present invention comprises about 100% of a NIFP.

[0040] It is preferred that the NIFP used in the intermediate layers ofthe present invention has a flexural modulus of greater than about10,000 psi, more preferably between about 30,000 psi and about 150,000psi and, most preferably, between about 55,000 psi and about 75,000 psi.This is particularly desirable when the intermediate layer is an innercover layer for a golf ball with a double-cover construction.Additionally, it is preferred that the NIFP has a Shore D hardness ofbetween about 25 and about 75 and, more preferably, between about 50 andabout 70. NIFP's of this nature include Kynar Flex® Series 2750 and 2800from Atofina Chemicals, Inc.

[0041] The intermediate layers employed in the golf balls of the presentinvention preferably have a thickness from about 0.005 inches to about0.125 inches, more preferably about 0.005 inches to about 0.085 inches,and most preferably about 0.030 inches to about 0.060 inches. The outerdiameter of the intermediate layers is preferably between about 1.500inches and about 1.650 inches, more preferably between about 1.550inches and about 1.640 inches.

[0042] The compositions of the present invention may also includefillers to adjust the density and/or specific gravity of theintermediate layer to a range of from about 0.90 to about 3.00. Toincrease the density of the NIFP (typically about 1.80 for Kynar Flex®PVDF), suitable fillers are generally inorganic, and include numerousmetals or metal oxides and salts such as tungsten, tungsten carbide,zinc oxide, tin oxide, calcium oxide, barium sulfate, zinc sulfate,calcium carbonate, barium carbonate, zinc carbonate, as well as clay, anarray of silicas, regrind (recycled core material typically ground toabout 30 mesh particle), high-Mooney-viscosity rubber regrind, andmixtures thereof. Alternatively, fillers having a specific gravity lessthan that of the NIFP may be used to reduce the specific gravity of theintermediate layer Such density-reducing fillers include foaming agents,blowing agents, micro balloons, cellular foams and other materialshaving a relatively large void volume. Typically, such fillers have aspecific gravity less than 1.00. Fillers may also include variouspolymers, ceramics, and glass microspheres that are solid or hollow, andfilled or unfilled, all of which are readily selected by one of ordinaryskill in the art. The preferred range of specific gravity for golf ballintermediate layers of the present invention is from about 0.90 to about1.50, more preferably from about 1.20 to about 1.30. The specificgravity of the golf ball depends upon the size of the finished ball andthe size and specific gravity of the core, the intermediate layer(s),and the cover.

[0043] The NIFP-based compositions for the intermediate layers of thepresent invention may be extruded as thin threads and wound about asolid core or a liquid-filled core to form a wound intermediate layer.Preferably the intermediate layer is compression or injection moldedabout the core. Alternatively, pre-formed intermediate layer half shellsare adhered onto the core using an adhesive. For proper adhesion, theadhesives include, but are not limited to, silane coupling agents;two-part adhesive of poly(VDF-HFP) and ketenes; polytetrafluoroethylene;fluoroethylene-propylene; high molecular weight polyethylene andpolypropylene; perfluoroacrylate; PVDF; VDF-HFP-TFE terpolymer;polychlorotrifluoroethylene; epichlorohydrin rubber with organicphosphonium; and mixtures thereof. The inner adhesion side of theintermediate layers may be treated to improve wettability by using anysuitable conventional processes such as flame treatment, coronatreatment, or chemical treatment. These processes tend to convert thesurface of the NIFP intermediate layers from a relatively low energysurface to a high energy, partially oxidized surface, which in turnimproves adhesion.

[0044] The golf ball cover of the present invention is preferably tough,cut-resistant, and selected from conventional materials used as golfball covers based on the desired performance characteristics. The covermay comprise one or more layers including an outer cover layer and atleast one inner cover layer. These layers may comprise thermoplasticand/or thermosetting materials include, without limitation, partially orfully neutralized ionomer resins; epoxy; polyurethanes comprisingpolyols and polyisocyanates; balata; vinyl resins; polyolefins;polyureas; polyamides such as poly(hexamethylene adipamide) andpoly(caprolactam); acrylic resins and blends thereof, block copolymerssuch as styrene-butadiene rubber and isoprene- or ethylene-butylenerubber; copoly(ether-amide) such as Pebax®; polyphenylene oxide resinsand blends thereof such as Noryl®; thermoplastic polyesters such asHytrel® and Lomod®; blends and alloys including polycarbonate withacrylonitrile butadiene styrene and polyvinyl chloride withacrylonitrile butadiene styrene; blends of thermoplastic rubbers withpolyethylene and propylene; and mixtures thereof. Conventional additivesfor the cover layer compositions include, but are not limited to,antioxidants; catalysts; colorants including pigments and dyes; hinderedamine light stabilizers; optical brighteners; UV absorbers; fillers;metals; plasticizers; surfactants; viscosity modifiers; compatibilityagents; dispersing agents; foaming agents; reinforcement agents; releaseagents; and mixtures thereof. Such additives may be incorporated in anyamounts that will achieve their desired purpose.

[0045] To minimize water vapor adsorption into the golf ball, it isdesirable that the cover of the golf balls has water vapor barrierproperty. While many WVB materials disclosed in prior art may beincorporated into the cover, it is preferred that the WVB material forgolf ball covers of the present invention is a NIFP as described above.A compatibilizer may be needed to blend the NIFP with the covermaterials mentioned above. Examples of the compatibilizer are describedin U.S. Pat. No. 6,274,669, the disclosure of which is incorporatedherein by reference in its entirety. The cover may comprise a singlecover layer, or an outer cover layer and at least one inner cover layer.In one embodiment of the present invention, at least one of the coverlayers is formed from a composition of about 1% to about 99% by weightof a NIFP, about 10% to about 50% by weight of a thermoplastic orthermosetting material such as an partially or fully neutralized ionomerresin or a polyurethane, and about 0% to about 15% by weight of acompatibilizer. Preferably, the cover of the present invention comprisesabout 100% of a NIFP.

[0046] Partially or fully neutralized ionomer resins for the golf ballcovers include copolymers or terpolymers of ethylene and an unsaturatedmonocarboxylic acid with an optional softening comonomer such asacrylate or methacrylate. The carboxylic acid groups in these ionomersinclude acrylic, methacrylic, crotonic, maleic, fumaric or itaconic acidpartially or fully neutralized by a cation such as lithium, sodium,potassium, zinc, magnesium, calcium, barium, lead, tin, aluminum, or acombination thereof, with lithium, sodium and zinc being preferred.Specific ionomers preferably include ethylene/(meth)acrylic acid,ethylene/(meth)acrylic acid/n-butyl acrylate, ethylene/(meth)acrylicacid/ethyl acrylate, and ethylene/(meth)acrylic acid/methyl acrylate,commercially available as Surlyn® from E. I. du Pont de Nemours andCompany, and as Ioteck® from Exxon.

[0047] Suitable polyurethanes for golf ball covers of the presentinvention include those disclosed in U.S. Pat. Nos. 6,392,002, 6,371,870and 6,210,294, incorporated herein by reference in their entirety, andgenerally comprise the reaction product of at least one polyisocyanate,polyol, and at least one curing agent. Any polyisocyanate available toone of ordinary skill in the art may be used in accordance with theinvention, preferably including, but is not limited to,4,4′-diphenylmethane diisocyanate (“MDI”); polymeric MDI;carbodiimide-modified liquid MDI; 4,4′-dicyclohexylmethane diisocyanate(“H₁₂MDI”); p-phenylene diisocyanate (“PPDI”); m-phenylene diisocyanate(“MPDI”); toluene diisocyanate (“TDI”); or a mixture thereof. It is wellunderstood in the art that the hardness of polyurethane is correlated tothe percent of unreacted NCO groups in the polyisocyanate. Preferably,the at least one polyisocyanate has less than about 14% unreacted NCOgroups, more preferably less than about 7.5%, and more preferably lessthan about 7.0%.

[0048] Any polyol available to one of ordinary skill in the art issuitable for use according to the invention, having saturated orunsaturated bonds, or substituted or unsubstituted aromatic and cyclicgroups in the hydrocarbon chain. Exemplary polyols include, but are notlimited to, polyether polyols, polyester polyols, polycaprolactonepolyols, and polycarbonate polyols. Suitable polyether polyols include,but are not limited to, polytetramethylene ether glycol (“PTMEG”),polyethylene propylene glycol, polyoxypropylene glycol, and mixturesthereof. Suitable polyester polyols include, but are not limited to,polyethylene adipate glycol; polybutylene adipate glycol; polyethylenepropylene adipate glycol; o-phthalate-1,6-hexanediol; poly(hexamethyleneadipate) glycol; and mixtures thereof. Suitable polycaprolactone polyolsinclude, but are not limited to, 1,6-hexanediol-initiatedpolycaprolactone, diethylene glycol initiated polycaprolactone,trimethylol propane initiated polycaprolactone, neopentyl glycolinitiated polycaprolactone, 1,4-butanediol-initiated polycaprolactone,PTMEG-initiated polycaprolactone, and mixtures thereof. Suitablepolycarbonates include, but are not limited to, polyphthalate carbonateand poly(hexamethylene carbonate) glycol. Preferably, the polyol of thepresent invention includes PTMEG.

[0049] The curing agent may be an amine, a hydroxyl-terminated curative,or a mixture thereof. Suitable amine curing agents are primary orsecondary amines include, but are not limited to,4,4′-bis-(sec-butylamino)-dicyclohexylmethane;1,4-bis-(sec-butylamino)-cyclohexane;3,5-dimehtylthio-2,4(2,6)-toluenediamine;3,5-diethyl-2,4(2,6)-toluenediamine; N,N′-dialkyldiamine diphenylmethane; 4,4′-diamino-3,3′-diethyl-5,5′-dimethyl diphenylmethane; 2,2′,3,3′-tetrachloro diamino diphenylmethane;trimethylene-glycol-di-p-aminobenzoate;polytetramethyleneoxide-di-p-aminobenzoate;4,4′-methylene-bis-(2-chloroaniline);4,4′-methylene-bis-(3-chloro-2,6-diethylaniline) (“MCDEA”);p,p′-methylene dianiline (“MDA”); m-phenylenediamine (“MPDA”);4,4′-methylene-bis-(2-chloroaniline) (“MOCA”);4,4′-methylene-bis-(2,6-diethylaniline) (“MDEA”);4,4′-methylene-bis-(2,3-dichloroaniline) (“MDCA”); isomers thereof andmixtures thereof. Suitable hydroxyl-terminated curatives are diols,triols, and tetraols that include, but are not limited to, ethyleneglycol; diethylene glycol; polyethylene glycol; propylene glycol;polypropylene glycol; polytetramethylene ether glycol;1,3-bis(2-hydroxyethoxy) benzene;1,3-bis-[2-(2-hydroxyethoxy)ethoxy]benzene;1,3-bis-{2-[2-(2-hydroxyethoxy)ethoxy]ethoxy}benzene; 1,3-propaneglycol; 1,4-butanediol; 1,5-pentanediol; 1,6-hexanediol;resorcinol-di-(β-hydroxyethyl)ether; hydroquinone-di-(β-hydroxyethyl)ether; and mixtures thereof. Both amine and hydroxyl-terminatedcuratives can include one or more saturated, unsaturated, halogen,aromatic, cyclic groups. Preferably, the curing agent for thepolyurethane cover compositions includes4,4′-bis-(sec-butylamino)-dicyclohexylmethane (Clearlink® 1000);1,4-bis-(sec-butylamino)-cyclohexane (Clearlink® 3000);3,5-dimehtylthio-2,4(2,6)-toluenediamine (Ethacure® 300);3,5-diethyl-2,4(2,6)-toluenediamine; 1,3-bis(2-hydroxyethoxy)benzene;1,3-bis-[2-(2-hydroxyethoxy) ethoxy]benzene;1,3-bis-{2-[2-(2-hydroxyethoxy)ethoxy]ethoxy}benzene; 1,4-butanediol,and mixtures thereof.

[0050] In a particularly preferred embodiment of the present invention,saturated (“aliphatic”) polyurethanes are used to form cover layers,preferably the outer cover layer. The thermoset polyurethanes may becastable, reaction injection moldable, sprayable, or applied in alaminate form or by any technical known in the art. The thermoplasticpolyurethanes may be processed using any number of compression orinjection techniques. The cover layers preferably have a Shore Dhardness of less than about 72, preferably about 40 to about 72, morepreferably about 50 to about 70 and most preferably about 55 to about65.

[0051] It is understood to one of ordinary skill in the art that theNIFP-based compositions described above for forming intermediate layersin golf ball may also be used, in part or in full, to form any of thecover layers in accordance with the present invention. Furthermore, golfball coating layers may also comprise one or more of the NIFP'sdisclosed herein.

[0052] The multi-layer golf ball of the invention may have an overalldiameter of any size. Although the USGA specifications limit the minimumsize of a competition golf ball to 1.680 inches in diameter or more,there is no specification as to the maximum diameter. Moreover, golfballs of any size can be used for recreational play. The preferreddiameter of the present golf balls is from about 1.680 inches to about1.800 inches. The more preferred diameter is from about 1.680 inches toabout 1.760 inches. The most preferred diameter is about 1.680 inches toabout 1.740 inches. In another alternative embodiment, the golf balls ofthe present invention have an overall maximum compression of about 90,preferably about 75 to about 85, more preferably about 80 to about 85and most preferably about 82.

[0053] A representative solid core composition in accordance with thepresent invention comprises an elastomeric polymer (“base rubber”), acrosslinking agent, and a free radical initiator. The base rubbertypically includes natural or synthetic elastomers such as naturalrubbers; balata; gutta-percha; synthetic polyisoprenes;styrene-butadiene rubbers; styrene-propylene-diene rubbers; chloroprenerubbers; acrylonitrile rubbers; acrylonitrile-butadiene rubbers;ethylene-propylene-diene terpolymers (“EPDM”); metallocene rubbers, andmixtures thereof. The elastomeric composition may also comprisepolypropylene resins; partially or fully neutralized ionomer resins;polyamides; polyesters; urethanes; polyureas; thermosetting orthermoplastic elastomers such as Pebax® (AtoFina), Hytrel® (DuPont) andKraton® (Shell Chemical); styrene-ethylene block copolymers; maleicanhydride or succinate modified metallocene catalyzed ethylenecopolymers; chlorinated polyethylenes; polysulfide rubbers;fluorocarbons; and mixtures thereof.

[0054] Preferably, the base rubber comprises at least about 40 pph byweight of at least one polybutadiene synthesized with cobalt, nickel,neodymium, and/or lithium catalysts. The polybutadiene preferably has acis- 1,4 content of at least about 90%, more preferably at least about95%. Also preferably, the polybutadiene has a Mooney viscosity of atleast about 30, a molecular weight of at least about 150,000 and apolydispersity of less than about 4.0. The base rubber may comprise ablend of two or more polybutadiene rubbers having different weightpercentages, catalysts, molecular weights, Mooney viscosity,polydispersity, filler contents, crosslinking agent contents, or cis-and trans-isomer contents.

[0055] The cross-linking agent may be formed from salts ofα,β-ethylenically unsaturated carboxylic acids having about 3 to about 8carbon atoms, such as methacrylic, acrylic, cinnamic, crotonic, formanicand maleic acids. Other cross-linking agents include unsaturated vinylcompounds. More preferably, the cross-linking agent is amono-(meth)acrylic acid or di-(meth)acrylic acid metal salt, wherein thecation is zinc, sodium, magnesium, or mixtures thereof. Even morepreferably, the cross-linking agent is zinc diacrylate (“ZDA”), zincdimethacrylate (“ZDMA”), or mixtures thereof. Of the common acrylatecross-linkers, ZDA has generally been found to produce golf balls withgreater initial velocity than ZDMA, therefore, the former is mostpreferred. The crosslinking agent may be present in an amount from about0 to about 70 pph of the base rubber. Base rubbers having little or noZDA has low water vapor transmission rates. They are less prone tomoisture absorption and related deterioration in playability andperformance because of the low permeability. On the other hand, highlevels of ZDA (greater than about 40 pph) provide desirable increases ininitial velocity and COR to the base rubber.

[0056] Suitable free radical initiators are typically a peroxide,preferably an organic peroxide, and include without limitation dicumylperoxide; n-butyl-4,4-di(t-butylperoxy)-valerate;1,1-bis(t-butylperoxy)-3,3,5-trimethylcyclohexane;α,α′-bis(t-butylperoxy)-diisopropylbenzene;2,5-dimethyl-2,5-di(t-butylperoxy)hexane; di-t-butyl peroxide; di-t-amylperoxide; di(2-t-butyl-peroxyisopropyl)benzene peroxide; laurylperoxide; benzoyl peroxide; t-butyl hydroperoxide; and mixtures thereof.Preferably, the peroxide initiator is dicumyl peroxide. The free radicalinitiator, at between about 70% and about 100% activity, is preferablyadded in an amount ranging between about 0.05 and about 15.0 pph byweight of the base rubber. More preferably, the amount of the initiatoradded ranges between about 0.1 and about 5.0 pph, and most preferablybetween about 0.25 and about 1.50 pph. The initiator may alternativelyor additionally be one or more of electron beams; gamma radiation;infrared radiation; ultra-violet radiation; X-ray radiation; or anyother high-energy radiation source capable of generating free radicals.Additives for the free radical initiators include free radicalscavangers, scorch retarders, stable free radicals, sulfur-based curingagents with optional accelerators, and mixtures thereof.

[0057] The polybutadiene rubber may be mixed with a cis-to-transcatalyst and an optional accelerator during molding to increaseresilience and/or decrease compression of the golf ball cores formedtherefrom. Suitable materials for the cis-to-trans catalyst andaccelerator are disclosed in U.S. Pat. Nos. 6,291,592 and 6,162,135, thedisclosures of which are incorporated herein by reference in theirentirety. Other core additives well known to the skilled artisan includefillers to adjust the density and/or specific gravity of the core,antioxidants to prevent the breakdown of the base rubber, processingaids, processing oils, plasticizers, dyes and pigments.

[0058] In a preferred embodiment, the present invention is directed toan improved multi-layer golf ball which comprises a core, a cover, andat least one intermediate layer disposed between the core and the cover.Preferably, the core has a compression ranging from about 10 to about100. The core preferably has a diameter of about 1.00 inch to about 1.65inches, more preferably about 1.25 inches to about 1.60 inches, and mostpreferably about 1.40 inches to about 1.58 inches. The cover is formedof one or more layers including inner and outer cover layers. It ispreferred that a finished golf ball made with such a core has a COR ofgreater than about 0.75, more preferably about 0.78 to about 0.85 andmost preferably about 0.79 to about 0.82.

[0059] Manufacturing of the golf balls of the present invention mayutilize any conventional processes employed in the golf ball art. Forexample, the solid cores can be either injection or compression molded.The intermediate layer is subsequently cast, melt extruded, injectionmolded, compression molded, heat shrink-wrapped, or spin-coated aboutthe core. It is important that the intermediate layer material be ableto sustain the temperatures applied during the application of the coverlayer. The cover layer or layers are then injection or compressionmolded or cast about the intermediate layer. The intermediate layers andthe cover layers may also be molded around any solid core by a reactionproduct injection molding process as described in U.S. Pat. No.6,392,002 and 6,371,870, which are incorporated herein, in theirentirety, by express reference hereto.

[0060] The invention, with respect to golf ball compositions comprisingnon-ionomeric fluoropolymers will now be described in more detail withrespect to the following non-limiting examples:

EXAMPLES

[0061] Sample intermediate layers of the present invention were moldedover polybutadiene cores having an outer diameter of 1.550 inches, anATTI compression of 73, and a COR of 0.796. Composition of the cores is:100 pph polybutadiene rubber (Bayer® CB-23), 25.5 pph zinc diacrylate(Sartomer® SR-526), 0.5 pph peroxide initiator, 5.3 pph zinc oxide, 10.5pph density-modifying filler (tungsten), 2.0 pph processing aids, and0.2 pph color pigment. The intermediate layers all had a thickness of0.035 inches. Compositions of the intermediate layers and theirrespective performance properties are listed in Table II below. TABLE IIGolf ball intermediate layers formed of non-ionomeric fluoropolymers Ex-Ex- Ex- Ex- ample ample ample ample Composition Control 1 2 3 4 Surlyn ®7940 50% Surlyn ® 8940 50% Kynar Flex ® 2900-04 100% Kynar Flex ®2850-04 100% Kynar Flex ® 3120-10 100% 75% Kynar Flex ® 2950-10 25%Properties ATTI Compression 79 80 93 89 83 COR @ 125 ft/s 0.804 0.7950.806 0.777 0.796 Water Absorption >0.5% <0.05% <0.05% <0.05% <0.07%

[0062] According to the data tabulated above, the intermediate layersformed from various non-ionomeric fluoropolymers, Kynar Flex® fromAtofina Chemicals, Inc. in particular, significantly reduced the waterabsorption in the samples in comparison with the Surlyn® ionomer basedintermediate layer in the controls. Specifically, the reduction in waterabsorption was at least one order of magnitude greater. This improvementis desirable in golf balls to prolong their shelf life and to enhancetheir durability. Other performance properties of the samples werecomparable to the controls. In particular, while the ATTI compression ofthe samples was slightly increased, there was no significant loss inCOR.

[0063] All patents and patent applications cited in the foregoing textare expressly incorporated herein by reference in their entirety.

[0064] Other than in the operating examples, or unless otherwiseexpressly specified, all of the numerical ranges, amounts, values andpercentages, such as those for amounts of materials and others, in thefollowing portion of the specification may be read as if prefaced by theword “about” even though the term “about” may not expressly appear withthe value, amount or range. Accordingly, unless indicated to thecontrary, the numerical parameters set forth in the specification andattached claims are approximations that may vary depending upon thedesired properties sought to be obtained by the present invention. Atthe very least, and not as an attempt to limit the application of thedoctrine of equivalents to the scope of the claims, each numericalparameter should at least be construed in light of the number ofreported significant digits and by applying ordinary roundingtechniques.

[0065] Notwithstanding that the numerical ranges and parameters settingforth the broad scope of the invention are approximations, the numericalvalues set forth in the specific examples are reported as precisely aspossible. Any numerical value, however, inherently contain certainerrors necessarily resulting from the standard deviation found in theirrespective testing measurements. Furthermore, when numerical ranges ofvarying scope are set forth herein, it is contemplated that anycombination of these values inclusive of the recited values may be used.

[0066] While it is apparent that the illustrative embodiments of theinvention disclosed herein fulfill the preferred embodiments of thepresent invention, it is appreciated that numerous modifications andother embodiments may be devised by those skilled in the art. Therefore,it will be understood that the appended claims are intended to cover allsuch modifications and embodiments, which would come within the spiritand scope of the present invention.

What is claimed is:
 1. A golf ball comprising: a core having acompression of from about 10 to about 100; a cover; and an intermediatelayer disposed between the core and the cover formed from a compositioncomprising a non-ionomeric fluoropolymer selected from the groupconsisting of partially fluorinated and perfluorinated olefins of fromabout 1 to about 12 carbon atoms; fluorinated alkyl α-olefins;fluorinated vinyl ethers of from about 1 to about 8 carbon atoms;perfluoro(methylvinylether); perfluoro(ethylvinylether); perfluoro(propylvinylether); partially fluorinated and perfluorinated dienes offrom about 1 to about 8 carbon atoms; fluorinated derivatives of1,4-butadiene; cis-isoprene; fluorinated acrylics;1,1-dihydropentadecafluoro-octylacrylate; and1,1-dihydropentadienefluorooctylacrylate.
 2. The golf ball of claim 1,wherein the fluorinated olefins comprise vinylidene fluoride; vinylfluoride, hexafluoropropylene; pentafluoropropylene;tetrafluoropropylene; trifluoropropylene; difluoropropylene;tetrafluoroethylene; trifluoroethylene; 1,2-difluoroethylene;chlorotrifluoroethylene; 1,2-dichlorodifluoroethylene; 1-chloro-1-fluoroethylene; or perfluorobutyl ethylene.
 3. The golf ball of claim1, wherein the fluorinated alkyl α-olefins comprise3,3,3,4,4-pentafluoro-1-butene; 3,3,3-trifluoropropene;1-hydropentafluoropropene; 2-hydropentafluoropropene;2-trifluoromethyl-3,3,3-trifluoro-1-propene; and mixtures thereof. 4.The golf ball of claim 1, wherein the non-ionomeric fluoropolymer isvinylidene fluoride homopolymer, vinylidene fluoride/hexafluoropropylenecopolymer, or vinylidenefluoride/hexafluoropropylene/tetrafluoroethylene terpolymer.
 5. The golfball of claim 1, wherein the composition further comprises cure sitemonomers; ionomeric fluoropolymers, chain transfer agents; peroxidecuratives; amine curatives; bisphenol curatives; cross-linking agents;redox initiators; co-curing agents; dispersion fillers;density-modifying fillers; foaming agents; antioxidants; reinforcingagents; plasticizers; lubricants; processing aids; pigments; or dyes. 6.The golf ball of claim 1, wherein the composition further comprises athermoplastic material comprising polyesterester block copolymers,polyetherester block copolymers, polyetheramide block copolymers,partially or fully neutralized ionomer resins, dynamically vulcanizedthermoplastic elastomers, hydrogenated styrene-butadiene elastomers withfunctional groups attached, thermoplastic polyurethanes, thermoplasticpolyesters, metallocene polymers; styrene-propylene-diene rubbers;polybutadienes; chloroprene rubbers; acrylonitrile rubbers;acrylonitrile-butadiene rubbers; ethylene/proprylene/diene terpolymers;polypropylene resins; epoxy; polyurea; styrene-ethylene blockcopolymers; maleic anhydride or succinate modified metallocene catalyzedethylene copolymers; chlorinated polyethylenes; polysulfide rubbers;fluorocarbons; or polymethylmethacrylate.
 7. The golf ball of claim 6,wherein the intermediate layer comprises about 10% to about 75% byweight of the non-ionomeric fluoropolymer, about 0% to about 25% byweight of the thermoplastic material, and about 0% to about 50% byweight of a density-modifying filler.
 8. The golf ball of claim 1,wherein the core has a resilience and comprises a cis-to-trans catalystin an amount sufficient to increase the resilience or decrease thecompression.
 9. The golf ball of claim 1, wherein the intermediate layerhas a flexural modulus between about 30,000 psi and about 150,000 psi.10. The golf ball of claim 9, wherein the intermediate layer has aflexural modulus between about 55,000 psi and about 75,000 psi.
 11. Thegolf ball of claim 1, wherein the intermediate layer has a materialhardness between about 25 and about 75 Shore D.
 12. The golf ball ofclaim 11, wherein the material hardness of the intermediate layer isbetween about 50 and about 70 Shore D.
 13. The golf ball of claim 1,wherein the intermediate layer has a thickness between about 0.005inches and about 0.085 inches.
 14. The golf ball of claim 13, whereinthe intermediate layer has a thickness between about 0.030 inches andabout 0.060 inches.
 15. The golf ball of claim 1, wherein theintermediate layer has an outer diameter between about 1.500 inches andabout 1.650 inches.
 16. The golf ball of claim 15, wherein theintermediate layer has an outer diameter between about 1.550 inches andabout 1.640 inches.
 17. The golf ball of claim 1, wherein theintermediate layer comprises a density-reducing filler, and wherein theintermediate layer has a specific gravity ranging from about 0.90 toabout 1.50.
 18. The golf ball of claim 1, wherein the core comprises acenter and at least one outer core layer.
 19. The golf ball of claim 18,wherein the at least one outer core layer comprises a non-ionomericfluoropolymer.
 20. The golf ball of claim 18, wherein the center issolid, hollow, liquid-filled, gel-filled, or gas-filled.
 21. The golfball of claim 1, wherein the intermediate layer is an outer core layer,an inner cover layer, or a wound layer.
 22. The golf ball of claim 1,wherein the cover comprises an outer cover layer and at least one innercover layer.
 23. The golf ball of claim 22, wherein the at least oneinner cover layer comprises a non-ionomeric fluoropolymer.
 24. The golfball of claim 1, wherein the cover is formed from a compositioncomprising a thermoplastic or thermosetting material comprisingpartially- or fully-neutralized ionomer resins; epoxy; polyurethanes;balata; vinyl resins; polyolefins; polyureas; polyamides; acrylic resinsand blends thereof; block copolymers; copoly(ether-amide); polyphenyleneoxide resins and blends thereof; or thermoplastic polyesters.
 25. Thegolf ball of claim 1, wherein the core has a compression of less thanabout 60 and a Shore D hardness of less than about
 60. 26. A golf ballconsisting of: a core having a compression of from about 10 to about 100and a resilience, and comprising a cis-to-trans catalyst in an amountsufficient to increase the resilience or decrease the compression; acover; and an intermediate layer disposed between the core and the coverformed from a composition comprising a non-ionomeric fluoropolymerselected from the group consisting of partially fluorinated andperfluorinated olefins of from about 1 to about 12 carbon atoms;fluorinated alkyl α-olefins; fluorinated vinyl ethers of from about 1 toabout 8 carbon atoms; perfluoro(methylvinylether);perfluoro(ethylvinylether); perfluoro (propylvinylether); partiallyfluorinated and perfluorinated dienes of from about 1 to about 8 carbonatoms; fluorinated derivatives of 1,4-butadiene; cis-isoprene;fluorinated acrylics; 1,1-dihydropentadecafluoro-octylacrylate; and1,1-dihydropentadiene-fluorooctylacrylate.